Radiators - Shop Manual Supplement
Article No. 85-12-26RADIATORS - SHOP MANUAL SUPPLEMENTAL INFORMATION - SECTION 27-04
LIGHT TRUCK F SERIES, BRONCO
F Series/Bronco Aluminum Core Radiators
FIGURE 15 NYLON TANK VACUUM BRAZED ALUMINUM RADIATOR - F SERIES & BRONCO WITH GASOLINE ENGINE:
The crossflow fin and tube design radiator used on F Series and Bronco vehicles with a gasoline engine is constructed with a vacuum brazed aluminum core and nylon end tanks (Figure 15). The nylon end tanks are attached to the aluminum core by bending tabs on the core header over the edge of the nylon tank. An O-ring gasket is placed between the nylon tank and the radiator core header to achieve a seal between the tank and the header. The nylon tanks are a molded one-piece design with the mounting brackets part of each tank.
Figure 16 - Header Tabs:
REMOVAL AND INSTALLATION
Radiator Tank - Removal
The radiator tanks are molded, glass-filled nylon and are attached to the core header by bending the header tabs (Figure 16) over the edge of the tank.
When removing a nylon tank, a screwdriver or one of the various special tools available can be used to open the header tabs. Some of these tools, including a screwdriver, may cause a small section of the header side to bend with the tabs as they are opened. This slight deformation is permissible, provided the tabs are opened only enough for tank removal. The header sides will usually return to the normal position when the tabs are crimped during tank installation.
Procedures are given for tank removal using a screwdriver or a Burroughs Tool BT-8260. Follow the manufacturer's instructions for other radiator tab opening and closing tools.
With Screwdriver
Figure 17 - Opening Header Tabs:
1. Insert the end of a medium tip screwdriver between the end of the header tab and the tank (Figure 17). Then, press the screwdriver blade against the tank to bend (pry) the tab away from the tank edge. Repeat this procedure for each tab.
NOTE: Bend (open) the tabs only enough for tank removal.
2. Lift the tank from the core header when all of the header tabs are bent away from the tank edge.
3. Remove the O-ring gasket from the header.
Figure 18 - Opening Header Tabs:
With Tool BT-8260
1. Insert the end of Tool BT-8260 between the end of the header tab and the tank (Figure 18). Then, push the tool handle down toward the core to bend the tab away from the radiator tank. Do not open the tabs more than is necessary for tank removal.
2. Repeat Step 1 for each header tab. Then, lift the tank from the header.
3. Remove the O-ring gasket from the header.
Installation
NOTE: If any header tabs are missing from an aluminum core, the core should be replaced.
1. Inspect the seal surface of the radiator core header to be sure it is clean and free of foreign material or damage.
Figure 19:
Figure 20 - RADIATOR DISASSEMBLED - F-150 THROUGH F-350 AND BRONCO:
2. Check the new O-ring to be sure it is not twisted (Figure 19).
3. Dip the new O-ring gasket in glycol or silicone or equivalent lubricant, and place the gasket in the header groove.
4. If the outlet tank is being replaced and is equipped with an oil cooler, (Figure 20), transfer the oil cooler from the replaced tank to the new tank as outlined.
5. Position the tank to the header using care not to scratch the tank sealing surfaces with the header tabs. Be sure the top and bottom of the tank is positioned properly with the other tank.
Figure 21 - TANK CLAMPED TO HEADER FOR CRIMPING - F SERIES AND BRONCO:
Figure 22 - LOCKING TYPE PLIERS:
6. Clamp the tank in position on the header with two header clamps as shown (Figure 21). Tighten the header clamps to compress the O-ring gasket.
7. If locking-type pliers are used to squeeze the header tabs against the tank, install a hex nut on the pliers adjusting screw.
8. With the jaws of the locking-type pliers closed and locked, turn the adjusting screw to position the jaws against the shank of a 13/32 inch drill bit. Then tighten the hex nut on the adjusting screw against the handle to lock the adjustment in place (Figure 22).
Figure 23 - CRIMPING HEADER TABS WITH LOCKING TYPE PLIERS - F SERIES AND BRONCO:
Figure 24 - CRIMPING HEADER TABS WITH BURROUGHS TOOL NO. BT 8260 - F SERIES AND BRONCO:
9. Squeeze the header tabs down against the lip of the tank base with the locking-type pliers while rotating the pliers toward the tank (Figure 23).
10. If a special crimping tool is used such as the one shown in Figure 24, follow the manufacturer's instructions.
Figure 25 - CRIMP ASSEMBLED HEIGHT - F SERIES AND BRONCO RADIATOR:
NOTE: It is, however, important that the assembled height of the crimp be 13/32 inch when measured from the bottom of the header to the top of the tab (Figure 25).
11. Remove the header clamps and squeeze the header tabs down that were behind the clamps.
12. Leak test the radiator at 145 kPag (21 psig). Most minor leaks at the header to tank seal can be corrected by again squeezing the header tabs down against the tank lip in the area of the indicated leak.
Radiator Core Repair
The only approved repair method for the aluminum radiator core requires a two-component epoxy material. The materials and supplies necessary to repair the aluminum core radiator are:
^ EPOXI-PATCH KIT No. 6C Aluminum Hysol Division of the Dexter Corporation Olean, New York 14760
^ Sandpaper and/or emery paper - 80 or 100 grit.
^ Stainless steel wire brush No. 23151, or equivalent Milwaukee Brush Manufacturing Company Menomonee Falls, Wisconsin 53501
^ 375 watt heating lamp
^ Mixing card and spatulas
Figure 26 - Repair Procedure:
Repair Procedure
1. Thoroughly clean the area around the leak with a stainless steel wire brush and, if necessary,emery paper to get to hard-to-reach areas. Use the brush on the epoxy as well as on the aluminum (Figure 26).
CAUTION: Do not use wire brushes that are not stainless steel.
2. Squeeze a bead (length) of repair material resin (Part A) on a clean, dry, disposable flat mixing surface. Use uniform pressure to obtain an even bead.
WARNING: OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON THE REPAIR MANUAL CONTAINERS.
3. Squeeze an equal bead (length) of hardener (Part B) parallel to the Part A bead. Mix Parts A and B together.
Figure 27 - Repair Procedure:
4. If it is necessary to have the epoxy flow to obtain a satisfactory repair, warm the core around the leak with a 375 watt heat lamp. Then apply the repair material to the leak (Figure 27).
Figure 28 - Repair Procedure:
5. Position the 375 watt heat lamp 305 mm (12 inches) from the repair and allow the repair to cure for two hours (Figure 28).
CAUTION: Do not position the heat lamp closer to the repair area than 305 mm (12 inches). Do not use a heat gun or overheat the repair material.
Figure 22 - LOCKING TYPE PLIERS:
6. Leak test the repair by clamping the tank to the header with No. 200 crimp clamps or equivalent (Figure 22).
7. After a successful leak test, install the radiator tank as outlined.
Oil Cooler Transfer or Replacement - Removal
1. Remove the outlet tank from the radiator as outlined.
Figure 20 - RADIATOR DISASSEMBLED - F-150 THROUGH F-350 AND BRONCO:
2. Remove the retaining nuts and washers from the oil cooler inlet and outlet connections. Then, lift the oil cooler from the radiator outlet tank (Figure 20).
3. Remove the rubber gaskets from the oil cooler inlet and outlet connections if the oil cooler is to be reused.
Installation
1. Install new rubber gaskets on the oil cooler inlet and outlet connections (Figure 20).
2. Position the oil cooler to the radiator outlet tank and insert the inlet and outlet connections through the holes in the outlet tank.
3. Install the flat washer and nut on each oil cooler connection to retain the oil cooler in the radiator outlet tank.
4. Tighten the oil cooler retaining nuts to 12-15 Nm (9-11 ft.lbs.).
5. Install the outlet tank on the radiator core header as outlined.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"